CN1774534B - Programmable tucking attachment for a sewing machine and method - Google Patents

Abstract

A pleating device (30) for a sewing machine has a pleating plate (34) with one end close to the fabric and a pleating plate actuator with its output end mechanically connected to the pleating plate. A controller (122) connected to the pleating plate actuator (44) can be operated to command the pleating plate actuator (44) to move the pleating plate (34) by a programmable displacement to form pleats in the fabric near the sewing machine presser foot. The sewing machine is then operated to sew within the pleats, and the pleating plate is then retracted. Repeating this cycle allows for the formation of continuous pleats of varying lengths within the fabric.

Description

Programmable pleating device and pleating method for sewing machine

technical field

The present invention relates generally to sewing machines and, more particularly, to methods and apparatus for pleating fabric during the sewing of mattresses.

Background technique

There are some sewing challenges in sewing the various components of the mattress together to form the finished product. One challenge is sewing around the corners of the components. For example, pillow-top mattresses are constructed to look as if a regular mattress has been topped with comforters or pillows for a more luxurious and comfortable look. The pillow top is attached to the mattress decking by gussets of folded material. There are a number of different techniques for sewing the edges of the corners of the pillow top to the corresponding corners of the tabs to give the stitched corners a consistent and pleasing appearance. However, all of these techniques require various manual operations, so incorporating the tabs into a pillow top mattress makes it more expensive for manufacturers to manufacture such mattresses than conventional mattresses.

Mitering tabs to form tabs around corners is known. Using a system, the operator cuts the protruding length of the previously formed tab stock at the measured location where the corner of the covering will be set; a mitered edge is formed on the tab stock before joining the tab stock to the stock. corner. However, due to the material and construction of the mattress cover fabric and the gusset fabric, the gusset and gusset often retract or deform at different rates when seated, thus slightly altering the relative orientation of the pre-mitred corners on the tab. In the corner position on the mattress fabric. Such changes frequently occur where the tabs are fully fabricated prior to assembly of the mattress cover. Because the mitered corners on the tabs do not line up precisely with the corners of the topper fabric, the operator must make adjustments when joining the tabs to the topper fabric, such as when the mitred corners need to be positioned correctly By pleating or trimming. Such adjustments cost the operator additional time and can lead to the possibility that the mitered corners will not be positioned correctly, or the corners will take on an uneven or undesirable appearance. Even if the operator were able to correctly position the mitered corners, the required fabric pleating or trimming would produce a mattress cover that would not have the desired appearance and would not be acceptable to all buyers.

Using another known system, a single machine is provided for making the tab and joining the border panels. The machine folds the panels, sews the panels together in their folded condition, and secures the border fabric to the panels. The resulting panels are then cut into sections and glued to the mattress fabric. In conjunction with this operation, a miter station is provided in close proximity to the bonder. When it is time to miter the corners of the tabs, as the operator approaches the mattress cover fabric, the bonder stops and the operator precisely measures the length from that point to the corner of the fabric. Mark equal lengths on tabs. The operator then pulls that portion of the tab toward the immediately adjacent miter station. Fold the tab across first at this point. Next, run two stitches on the tab from the folded edge inwards with the sewing machine. Each stitch is at an angle of 45° relative to the folded edge of the tab such that the two stitches form an angle of 90° with respect to each other. The sewing machine is preferably programmed to sew exactly the desired number of stitches needed for the miter. All the operator has to do is wait until the needle thread is finished, turn the tab through 90° and start the machine again. Afterwards, the triangular section defined by the needlework and the folded edges are cut from the tab, either automatically or manually, and the tab is then removed from the mitering station. While more automated, this operation still requires an operator to perform multiple steps to form the corner during the process of joining the tab to another object.

Accordingly, there is a need for a more improved method of reliably joining a tab to a mattress component, such as a mattress top deck.

Another difficulty in sewing at the corners of a bedding assembly arises in joining the top decking to the edge of a bedding foundation, such as a box spring. Using a known method, the edge of the top cover fabric is sewn to the edge of the quilt frame fabric along the outer edge of the quilt frame. The joints between the corners of the upper deck can be pre-cut so that there is little or no excess fabric at the corners. If the corners in the top facing fabric are not pre-cut, the operator of the machine must pleat the fabric to adjust the excess fabric at the corners. Unless the operator is extremely skilled, sometimes the product has a very uneven appearance because the quilt rack assembly is bulky and difficult to control around corners. Furthermore, because the seam joints are at the edges of the comforter frame, the top cover material is often still visible even after the mattress is placed on the comforter frame.

To provide a more finished look, it is also known to join the quilt frame border fabric to the top cover fabric inside the outer edge of the quilt frame, for example 3-4 inches inside the edge of the quilt frame. However, to provide the desired finish, the futon frame border fabric needs to be mitered when forming the futon frame border fabric around the corners of the futon frame. The mitering of the border fabric of the quilt frame is accomplished by a technique similar to that described above. While improving the appearance of the finished quilt rack, the additional labor required adds significantly to the manufacturing cost of the quilt rack.

Therefore, there is also a need for a more improved method of joining a top cover fabric to the border fabric of a quilt frame.

Contents of the invention

The present invention provides a pleating device for a sewing machine that facilitates sewing one material to another around corners. The pleating device of the present invention allows pleats of different lengths to be formed in the fabric. Thus, the tucking device of the present invention provides greater flexibility in controlling the fullness of the fabric as well as the appearance and style of the finished fabric when sewing corners. Furthermore, using the pleating device of the present invention, the formation of each pleat can be automatically and precisely controlled; therefore, the formation of pleats around corners can be repeated from one corner to another. The pleating device of the present invention automatically generates the pleats of the fabric so as to guide the fabric to sew stitches around the corners with minimal operator intervention; thus, high-quality fabric corners can be sewn without significantly increasing manufacturing costs.

The pleating device of the present invention is particularly useful in the joining process of components used in the manufacture of mattresses or quilt frames. The ability to program successive pleats of different lengths during sewing the corners of two components together allows a quilt manufacturer to produce different looks that are specific to that manufacturer. In addition, since the operator does not need to intervene during the formation of the pleats of the individual fabrics, the operator can concentrate on the overall processing of the fabrics. The end result is a more efficient fabric pleating and sewing process that is less labor intensive for the operator while producing a more consistent and higher quality product.

According to the principle of the present invention and according to the described embodiments, the present invention provides a pleating device for a sewing machine. The pleating device has a pleating press with an end close to the fabric and a pleating press actuator whose output end is mechanically engaged with the pleating press. A controller connected to the pleating sheet actuator has a memory for storing programmable displacements of the pleating sheet, and the controller is operable to command the pleating sheet actuator to drive the pleating sheet to move movable Program the offset to form pleats in the fabric close to the sewing machine foot. Thereafter, the controller may be operated to command the pleating sheet actuator to move the pleating sheet in the opposite direction. Thus, repeating the above-described cycle of operations allows continuous pleats of different lengths to be formed in the fabric, thereby facilitating sewing curved stitches in the fabric.

In one aspect of the present invention, the tucking flap and the tucking flap actuator are pivotally connected to a support connected to the sewing machine, thereby allowing the tucking flap and the tucking flap actuator to rotate to an open position to allow Greater access to sewing machine feet and needles.

In another embodiment of the present invention, there is provided a method for forming pleats in a sewable fabric on a sewing machine having a presser foot for securing the fabric and a presser foot for sewing the fabric held by the presser foot. machine needle. First, position the fabric under the presser foot; then, move the pleating tab to touch the fabric under the presser foot. Thereafter, the pleat blade is moved towards the presser foot through a programmable displacement to form pleats in the fabric under the presser foot. Then operate the sewing machine to sew multiple stitches on the pleats and retract the pleating tabs. In one aspect of the invention, the method is repeated until the desired number of pleats are formed.

These and other aspects and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.

Description of drawings

Figure 1 is an end view of a sewing system according to the principles of the present invention showing the tucker mechanism.

FIG. 2 is a partially enlarged perspective view illustrating a delivery actuator of the tucker device in FIG. 1 .

Figure 3 is a top view of the sewing system illustrating the tucker device of Figure 1 rotated to its open position.

Fig. 4 is a partially enlarged perspective view illustrating the lifting cylinder of the pleating device in Fig. 1 .

Fig. 5 is a schematic block diagram illustrating the control of the tucker device in Fig. 1 .

Figure 6 is an enlarged partial perspective view of a corner of a mattress with a pillow top representing one application of the pleating device of Figure 1 .

FIG. 7 is an enlarged fragmentary perspective view of a cutting board and decking guide used in conjunction with the pleating apparatus of FIG. 1. FIG.

8A and 8B are end views of the sewing machine illustrating the operation of the tucker device of Fig. 1. Figs.

Fig. 9 is a flow chart illustrating the operation of the tucker device in Fig. 1 .

FIG. 10 is a partially enlarged perspective view of a corner of a quilt rack representing another application of the pleating device of FIG. 1. FIG.

Figure 11 is an enlarged fragmentary perspective view of a corner of a mattress with a box top, representing yet another application of the pleating device of Figure 1 .

Detailed ways

Referring to Figure 1, a sewing system 20 has a sewing machine 22 secured to a base plate 24 in known manner. The sewing machine comprises a presser foot 26 and a needle 28 which reciprocates and which carries needle and bobbin threads in known manner. The sewing machine 22 is a commercial sewing machine that performs lockstitching. Overlocking is a known technique for knitting needle and bobbin threads and will not be further described here. The tucking device 30 in FIG. 1 includes a tucking blade 34 secured within a tucking arm 36 . The upper end 38 of the tucker arm 36 is pivotally attached to a swivel pin or trunnion 39 which is supported on a pair of opposed bearing blocks 41, 60 (FIG. 2) which Then be fixed on the support 42.

A pleating blade actuator 44 is also fixed to the bracket 42 and operates to provide pivotal movement of the pleating arm 36 to cause the pleating blade 34 to form pleats in the fabric in a manner to be described below. Pleated sheet actuator 44 is powered by actuator 46, such as an AC servo motor. The servo motor 46 is attached to a generally U-shaped motor bracket 48 . The motor bracket 48 has opposed legs 50 , 52 extending outwardly from the motor 46 in a direction generally parallel to the motor output shaft, which is formed as a ball screw 54 . Opposed legs 50 , 52 are pivotally connected to respective opposed swivel pins 56 , 58 , which are in turn supported by respective opposed brackets 60 , 62 .

The ball nut 64 is installed on the ball screw 54 and is pivotally connected to the opposite rotary pin 65 , and the rotary pin 65 is supported by a U-shaped clip 66 formed at one end of the driving link 68 . The drive link 68 is pivotally connected to a rotary pin 71 located in a pair of opposite bearing seats 70 protruding from the bracket 42 . A lower end 72 of the drive link 68 is pivotally received within an upper end 74 of a shackle 76 . The lower end 78 of the hook is pivotally connected to a shaft 80 which is connected to the tucker arm 36 . Therefore, when the servo motor 46 works to make the ball nut 64 move toward the motor 46 along the ball screw 54 , the driving link 68 rotates clockwise relative to the rotary pin 71 , as shown in FIG. 2 . Clockwise rotation of the drive link 68 rotates the tucker arm 36 clockwise relative to the pivot axis 40 , thereby moving the tucker blade 34 ( FIG. 1 ) away from the presser foot 26 . Reverse operation of the servo motor 46 moves the ball nut 64 away from the motor 46 , thereby rotating the drive link 68 counterclockwise relative to the rotary axis 82 and causing the tucker arm 36 to also rotate counterclockwise relative to the rotary axis 40 . Counterclockwise rotation of the pleating arm 36 moves the pleating blade 34 closer to the presser foot 26 . It can be understood that the movement of the ball nut 64 along the ball screw 54 can be controlled by programming, so the stroke of the pleating pressing piece 34 and the length of the pleats of the produced fabric can also be controlled by programming.

As shown in FIG. 2 , the bracket 42 is connected by its inner end 84 to a sleeve 86 which is rotatably fixed on a shaft 88 . The shaft 88 is secured by its lower end to an arcuate support plate 90 having a plurality of positioning slots 92 . The locking backing plate 94 extends horizontally from the underside of the bracket 42 and rests on the support plate 90 . A spring-loaded release pin 96 is secured to the locking pad and the release pin 96 is urged such that its lower end is seated within one of the detent slots 92 . The position of the positioning slot enables the support 42 and all components in the pleating device connected to the support 42 to be located in an ideal working position. The release pin 96 has a knob 98, which is convenient for the operator to lift the release pin from the positioning slot. With the positioning pin 96 in the raised position, the frame 42 and all components of the pleating device supported on the frame 42 can rotate counterclockwise relative to the axis of rotation 100 defined by the shaft 88, as shown in FIG. 2 . The support plate 90 provides the necessary support for the frame 42 and the associated components of the pleating device as the frame 42 rotates. When the bracket 42 is rotated through approximately 90° to the open position shown in FIG. 4, the release pin 96 is pressed into the detent 92a (FIG. 2), thereby locking the tucker device in the retracted position. This retracted position allows the operator free access to the presser foot 26 and needle 28 . Raising the release pin 96 from the detent 92a allows the frame 42 and associated tucker components to rotate clockwise back to the desired working position.

Referring to FIG. 4 , arcuate support plate 90 is secured to and supported by drive plate 101 which in turn is secured to the end of piston rod 102 , 104 of each cylinder 106 , 108 . The operation of the cylinders 106, 108 causes the components of the drive plate 101, the support plate 90, the frame 42 and the associated pleating device 30 to be raised and lowered. The air cylinders 106 , 108 are connected to a right angle mount 110 , which in turn is supported by the sewing machine 22 and connected to the frame 32 .

Returning to FIG. 1 , the pleating press 34 is secured to the lower end of the pleating press mounting rod 112 , which is slidably supported within the pleating arm 36 . The upper end 114 of the fixed rod 112 is connected to a piston rod 116 which is supported within a guide 118 . Therefore, by operating the air cylinder 120, the operator can move the piston rod 116 and the pleating presser fixing rod 112 up and down, thereby respectively retreating and advancing the pleating presser 34 with respect to the presser foot 26.

Referring to Figure 5, the operation of the pleated panel apparatus 30 is controlled by a programmable controller 122, such as a commercially available programmable logic controller. The controller 122 includes a user input/output (I/O) interface 124 that provides various user-operable input devices such as buttons, switches, etc., and various sensory perceptible output devices such as lights, visual displays Such as LCD screen and so on. User I/O interface 124 allows a user to command the operation of the various servo motors and cylinders connected to the output of controller 122 . Thus, by activating an input device on user I/O 124, an operator can command controller 122 to provide an output signal to change the state of solenoid 125. A change in the state of the solenoid 125 will change the throttle range (porting) of pressurized gas flowing from the air source 126 to the cylinders 106, 108 for lifting and lowering the pleated sheet, thereby causing the cylinders 106, 108 to raise or lower their respective piston rods 102, 108, 104 (Fig. 4). In a similar manner, the operator uses the user I/O 124 to command the controller 122 to provide an output signal to the solenoid 127 causing the pleating plate retraction cylinder 120 to retract or advance the pleating press 34 . Additionally, the user I/O allows the operator to enter parameters for the pleating operation, such as the number of pleats to be placed around corners, the length of each pleat, the number of sewing threads between pleats, and the like.

The pleating controller 122 receives inputs from position feed and stop sensors 128, 129, respectively, and a foot switch 130, which is used by the operator to initiate the pleating cycle. The tucker controller 122 is connected to the sewing machine controller 131 through a digital I/O line 132 that allows the tucker controller 122 to provide operational commands to the sewing machine controller 131 . The sewing machine controller receives the operator's commands through the user I/O 133 and the foot switch 134, and provides output signals to operate the sewing head servo motor 135 and other components on the sewing machine 22 in a known manner. The pleat controller 122 has a ball nut position memory 136 for storing the desired position of the ball nut 36 corresponding to the pleat length input by the operator to determine the length of each pleat.

Referring to FIG. 6 , a mattress 140 has a pillow top 141 sewn to one side of a tab 142 sewn to an upper decking 143 of a mattress body 147 on the other side. The mattress body 147 is generally of innerspring construction. As previously mentioned, it is relatively easy to sew the pillow top 141 , panels 142 and top decking 143 together along the straight edge 144 of the mattress body 147 . However, it is very difficult to sew the tabs 142 around the corners 145 of the mattress body 147, and there have been various prior art techniques for sewing the tabs 142 around the corners. Using the present invention, pleats 146 are formed in the tab 142 to guide the sewing of the upper decking material 143 and the tab 142 around the corner 145 so the appearance of the tab is predictable and pleasing and repeatable. Applying this seam sewing, with reference to FIG. An unfolded strip of fabric 150 is manually delivered to inlet port 152 and out of outlet port 154 via folder 148 . As the strip of fabric 150 passes through the folder 148 , the strip of fabric 150 is folded over itself to form opposing sides, and the folded configuration of the folded fabric 150 is referred to herein as the tab 142 .

Referring to FIG. 7 , the pleating device 30 also includes an anvil 156 secured to the inner end 158 by a locking screw 160 . By loosening the locking screw 160 , the anvil 156 can be rotated counterclockwise about an axis of rotation 162 defined by the locking screw 160 away from the presser foot 26 . The anvil 156 is held in place by the positive stop surface 164 on the stop 166 when the anvil 156 is rotated clockwise back to its illustrated position. Then, the locking screw 160 is tightened to secure the anvil 156 . The anvil 156 has a sloped surface 167 that provides support for the pleating tab 34 beneath the tab material as it forms pleats within the tab. The decking guide 168 is secured to the underside of the anvil 156 by a locking nut 170 and a screw 172 that slides in a slot 174 . By loosening the locking nut 170 , the decking guide 168 can be slid into different positions in a direction parallel to the slot 174 . The decking guides are positioned such that when the edges of the tabs are aligned with the inside edges (not shown) of the decking guides, the sides of the folded tab are equal in width.

In use, a first embodiment of application is sewing the tab 142 ( FIG. 6 ) to the upper decking fabric 143 . After the desired pattern and style has been determined, the operator uses the user I/O 124 to input parameters related to the number of pleats used to form the corner, the length or size of each pleat, and the number of sewing threads to be sewn between the pleats . These parameters are stored in the number of pleats memory 136 , the ball nut position memory 137 and the number of sewing threads memory 138 . It will be appreciated that the length of each pleat can be easily converted to the position of the ball nut.

First, in the manner described above, the operator lifts the release pin 96 ( FIG. 2 ), allowing the tucker device 30 to be rotated away from the presser foot 26 ( FIG. 3 ), thereby allowing the operator full access to the needle 28 . Thread and bobbin thread are then threaded on needle 28 in known manner. Referring to FIG. 7 , the upper decking stock 143 is fed over the base plate 24 and decking guides 168 and under the anvil 156 . The facing material 143 is oriented such that a straight edge 144 is positioned under the presser foot at the point where the sewing operation is initiated. Then, the pleating device 30 is turned clockwise until the release pin 96 enters the positioning groove 92b (FIG. 3) to secure the pleating device 30 in its operative position.

Thereafter, the operator uses the user I/O 124 ( FIG. 5 ) to command the controller 122 to provide an output signal to the solenoid 127 to operate the pleating press retracting cylinder 120 to retract the pleating press 34. The panel 150 is then manually conveyed through the folder 148 to form the tab 142 and place the tab under the presser foot 26 . The operator then again uses the user I/O 124 to command the controller to advance the pleating sheet 34, as shown in Figure 8A. The pleating tab 34 is now located above the tab 142 and on the upstream side of the presser foot 26 , ie to the right of the presser foot 26 as shown in FIG. 6 . Next, the operator commands the controller 122 to start the sewing head motor 135, and conveys the upper pavement fabric 143 and the connecting piece 142 from right to left under the presser foot 26, as shown in Figure 8A, while the machine needle 28 reciprocates, and these Fabric pieces are sewn together. As the corner 145 of the upper surfacing 143 is approached, the edge of the corner 145 passes the position feed sensor 128 (FIG. 1). The sensor 128 then detects the reflection from the reflector 178 and the output of the sensor 128 changes state. Upon detecting a state change, the pleating controller 122 provides a deceleration signal to the sewing machine controller 131 via the digital I/O 132. The sewing machine controller 131 commands the sewing head motor 135 to slow down to a low speed. The edge of the corner 145 then passes under the stop sensor 129 and the reflected signal from its reflector 180 (FIG. 7) causes its output to change state. Upon detecting a state change, the tucker controller 122 provides a stop command to the sewing machine controller 122 .

Then, the operator presses the foot switch 130 to command to start the operation of the corner cycle, as shown in FIG. 9 . At 804, the controller 122 first determines whether the ball nut 64 and tucker arm 36 are in their home or home positions. Typically, when performing a corner cycle, the ball nut starts from a common home or initial position, eg, with reference to FIG. 2 , closer to the abutments 60 , 62 than the position of the ball nut 64 is shown. In this position, the pleating flap 34 is at its furthest from the presser foot 26 , as shown in FIG. 1 . If the controller 122 determines that the ball nut 64 is not in its desired position, then at 805 the controller 122 provides an appropriate output signal to the pleating servo motor 46 to move the ball nut 64 to the initial position.

Next, at 806 , the controller 122 reads the ball nut advance position from the ball nut position memory 137 . Next, at 808 , the controller 122 provides an output signal to the pleating sheet servo motor 46 to rotate the ball screw 54 in a direction that moves the ball nut 64 outwardly away from the mounts 60 , 62 . As the ball nut 56 moves outward, the pleating blade 34 turns or advances toward the presser foot 26 . During this process, the pleating tab 34 moves the tab 142 over the ramp 167 of the anvil 156 and causes one portion of the tab to underlie the other to form the pleat 146a (FIG. 8B). The continuous movement of the pleating blade 34 pushes the pleats under the presser foot 26 and needle 28 . The distance the ball nut 56 travels along the ball screw 54 will determine the stroke length of the pleating tab 34, which in turn determines the length of the pleats 146a formed in the tab. Then at 810, the controller 122 determines whether the ball nut has reached its desired position where the pleating tab 34 is at its desired pleat length L. When this occurs, then at 812 the controller 122 provides a stop signal to the servo motor 46 . It will be appreciated that the length L of the pleats 146a can be varied and can be changed from one pleat to another by programming and storing different ball nut positions into the ball nut position memory 137 .

Next, at 814 , the controller 122 provides a start signal to the sewing head servo motor 135 , causing the needle 28 to reciprocate and cause the upper surfacing 143 and the tab 142 to be sewn together while being conveyed through the needle 28 . During this sewing process, the top decking 143 and the panel 142 are manually guided by the operator so that the pleats in the tab 142 and the top decking 143 are sewn together along a seam that lies on an arcuate path. The sewing machine controller 131 receives feedback signals representing the rotation of the sewing head servo motor 135, and these feedback signals are transmitted to the pleating controller 122 via the digital I/O 132. The tucker controller reads the desired number of sewing threads to sew between pleats from the sewing thread number memory 138 . When the pleating controller 122 detects at 816 that the required number of sewing threads has been sewn, the controller 122 generates a stop command at 818 to the sewing machine controller 131, and then the controller 131 commands the sewing head servo motor to stop. Afterwards, the pleating controller 122 reads the retracted position of the ball nut from the ball nut position memory at 819 and provides an output signal, and at 820 commands the pleat pressing servo motor to operate in reverse, so that the ball nut 64 moves toward its starting position . When the commanded position of the ball nut is detected at 822 , the controller 122 then provides a stop command to the pleating sheet servo motor 46 at 824 . Pleat controller 122 then reads the number of pleats to be formed around corner 145 from pleat count memory 136 and determines at 826 whether the last pleat has been formed. If not, the process returns to reading the next ball nut position at 806, which determines the length of the next pleat to be formed.

The corner cycle then continues to automatically repeat the above process to continuously form pleats of the same or different lengths, allowing the operator to guide the tab 142 and sew stitches around the corners of the upper decking 143 . When the last pleat formation is detected by the pleating controller 122 at 826, the controller 122 provides a corner end signal to the sewing machine controller 131 via the digital I/O 132, which allows the operator to operate in a conventional manner independently of the pleating device 30. Sewing machine to sew along the next straight seam.

Repeating the above process, the edges of the gusset 142 are sewn around all four corners of the upper surfacing 143, and the operator is now sewing on the starting straight line 144 where the sewing process begins. When there is about 6 inches of edge left unsewn, the operator stops the sewing head servo motor 135 and raises the locking pin 96 (Fig. Wire. Here, the operator has access to the presser foot 26 and the needle 28 and can manually gather and sew the remaining straight edges in known manner. If desired, the operator can more easily access the sewing machine needle by using the user I/O 124 (FIG. 5) to command the tucker controller 122 to provide an output signal to switch the state of the solenoid 125. This enables pressurized fluid to enter the pleating sheet lift cylinders 106, 108 and cause the cylinders 106, 108 to lift the pleating device 30, thereby providing additional space.

It should be noted that some of the panels 142 are typically sewn to a piece of upper facing fabric prior to the operation using different input parameter values related to the number of pleats, the same or different lengths of each pleat, and the number of sewing threads between the pleats 143 on. By varying these parameters, corners of different shapes and styles can be produced; it is entirely possible for manufacturers to produce unique corner styles. After the desired values for these parameters are determined, these values can be entered into the tucker controller 122 via the user I/O 124 .

Referring to Figure 10, in an alternative application, the tucker device 30 can be used to sew an upper decking 186 to a quilt frame border 188 that has been folded onto the upper decking. In this application, the folder 148 is removable from the tucker device 30 . The upper decking fabric 186 is conveyed under the cutting block 156 at the fabric 143 place. Additionally, a quilt frame border panel 188 may be placed over the cutting board 156 and under the pleating tab 34 in a manner similar to that described above with respect to the tab 142 . Again, sewing machine 22 is operated in known manner to sew straight seam 190 (FIG. 10). When corner 191 is reached, the operator activates foot switch 130 to execute the corner cycle of Figure 9, sewing pleats 192 in quilt frame border panel 188 in the manner described above.

Referring to FIG. 11 , in another alternative application, a mattress 193 is constructed with a body or spring assembly 194 having a Euro-top 195 attached to the mattress 193 . The Euro top 195 is generally thicker than the pillow top 141 in Figure 6, and structures with Euro tops are generally of higher quality on the market. Various constructions of the Euro top 195 may include spring assemblies, foam padding and/or other fabrics. Typically, to attach the euro top sheet 195 to the mattress body 194, a separate gusset type fabric is sewn between the peripheral edge of the euro top sheet 195 and the peripheral edge of the mattress body 194 in a manner similar to that described above regarding the use of a gusset. 142 ( FIG. 6 ) the sewing pattern for joining the pillow top 141 to the mattress body 147 . However, the tucker device 30 in the sewing system 20 of FIG. 1 has the ability to create an alternative attachment system.

As shown in FIG. 11 , the euro top layer 195 has a border panel 196 that is joined or sewn along its upper edge 197 to the peripheral edge of a generally planar top panel 198 . The lower portion of the border panel 196 is formed as an integral panel attachment or compensating section 199 that is attached to the outer edge of the upper decking panel 201 . Thus, the border panel 196 is attached to the upper decking panel without the need for a separate panel of attachment panel. This is accomplished by first positioning the upper decking stock 201 onto the base plate 24 ( FIG. 7 ) and then positioning the border stocking 196 onto the anvil 156 . The lower edge 204 of the border stock 196 is generally aligned with the outer edge of the pavement stock 201; The stitch 200 joining the border stock 196 to the upper deck stock 201 begins at a straight edge portion parallel to the lower edge 204 . In the manner described above, when the corner 202 of the upper decking panel 201 is reached, a corner cycle is performed while the panels 196 , 201 are guided around the corner 202 . During this process, pleats 203 are formed in the border fabric 196 to control the fullness of the border fabric 196 as the border fabric 196 is guided around the corner. The process described above continues until the compensating portion 199 is completely formed by the stitches 200 around the periphery of the upper decking material 201 . While the stitching 200 makes the border fabric 196 and compensating portion 199 appear to be two separate strips of fabric, they are actually one. Thus, the pleating device 30 allows a quilt manufacturer to more easily, efficiently and economically produce different shapes and styles in Eurotop style mattress constructions.

The tucker device 30 provides a fabric pleat whose length can be programmed to vary, thereby providing greater flexibility in controlling the fullness of the fabric when sewing around corners. Furthermore, with this pleating device 30, the formation of each pleat can be automatically and precisely controlled so that around-corner pleats can be repeatedly formed from one corner to another. The pleating device 30 minimizes operator intervention in forming pleats around corners so that high quality fabric corners can be sewn without significantly increasing tooling costs. The pleating device 30 is particularly useful in connecting components used in the manufacture of mattresses or quilt frames. The ability to design continuous pleats of different lengths when sewing the corners of two components together allows a quilt manufacturer to produce different shapes that are unique to that manufacturer. In addition, since the operator does not need to control the fabric during the formation of the pleats of the individual fabrics, the operator can concentrate on the overall fabric processing. The end result is a more efficient fabric pleating and sewing process that is less labor intensive for the operator while producing a more consistent and higher quality product.

While the invention has been illustrated by the description of various embodiments, and the description of these embodiments has been described in great detail, it is the applicant's intention not to limit the scope of the appended claims, or to limit in any way to these details. Additional advantages and modifications will readily occur to those skilled in the art. For example, in the described embodiment, the pleating sheet actuator is described as a DC servo motor, however it will be appreciated that in alternative embodiments, the pleating sheet actuator can be any programmable actuator actuators, such as programmable cylinders, which can be pneumatic, hydraulic or electric. Additionally, the pleating sheet actuator could also be a stepper motor or a programmable AC motor. Similarly, in other alternative embodiments, the rod up actuator can also be implemented using any of the actuators described above.

It is also understood that the linkage mechanism of the pleating press drive train can be changed or varied without adversely affecting the operation of the pleating press. Furthermore, while in the above application the pleating device is used for right-angled corners, it will be appreciated that the pleating device can be used to form pleats in any arcuate or curved stitch. Also, in the embodiments described above, the sensors 128, 129 are used to detect the presence of corners, but it will be appreciated that in alternative embodiments, the presence or initiation of corners could be detected by the sewing machine operator using the sensors 128, 129.

In the described embodiment, the pleating device 30 is shown secured to the sewing machine 22, but it will be appreciated that in other alternative embodiments, the pleating device can be suspended or free standing in its operative position. support structure support. In addition, during operation, the pleating device 30 rotates the pleating press piece 34 along a path substantially parallel to the straight line direction of the sewing machine conveying the fabric through the needles. It will be appreciated, however, that the gatherer 34 can be manipulated and/or positioned so that the path of the gatherer 34 is not parallel to the straight line in which the sewing machine conveys the material past the needles. This may be required when forming pleats with different shapes or to provide the operator with easier access to the presser foot and needle.

Therefore, the invention in its broadest aspects is not limited to the specific details shown and described. Accordingly, departures may be made from the details described herein without departing from the spirit and scope of the appended claims.

Claims (9)

1. A method for sewing a first fabric supported on a base plate of a sewing machine onto a second fabric when the second fabric is pleated by a pleating device, wherein the sewing machine has presser feet for securing the first and second fabrics and a reciprocating needle for sewing together first and second fabrics, the method comprising: Position the first fabric on the sewing machine base plate under the presser foot; Position the cutting board above the first fabric and below the pleating tab; Position the second fabric on top of the cutting board and under the presser foot next to the first fabric; a) advancing the pleating tab toward the presser foot, thereby engaging the second fabric with the pleating tab and forming pleats of programmable length in the second fabric over the first fabric; b) operating the sewing machine to deliver the pleats in the second fabric and the reciprocating needles of the first fabric, and sewing a required number of sewing threads on the pleats in the second fabric and the first fabric; c) retract the pleating tab away from the presser foot; and Repeat the above steps of a) advancing the pleating tab towards the presser foot, b) operating the sewing machine, c) retracting the pleating tab to form the desired number of pleats in the second fabric and sewing the pleats to the first fabric. 2. The method of claim 1, wherein the method further comprises guiding during the process of a) advancing the pleating press toward the presser foot, b) operating the sewing machine, c) retracting the pleating press The first and second panels such that stitches are formed along an arcuate path connecting the pleats in the second panel to the first panel. 3. The method of claim 2, further comprising, during step b) operating the sewing machine, feeding the first and second panels through reciprocating needles and sewing the first and second panels together. 4. A method for sewing a first fabric supported on a base plate of a sewing machine onto a second fabric when the second fabric is pleated by a pleating device, wherein the sewing machine has presser feet for securing the first and second fabrics and a reciprocating needle for sewing together first and second fabrics, the method comprising: Position the first fabric on the sewing machine base plate under the presser foot; Position the cutting board above the first fabric and below the pleating tab; Position the second fabric on top of the cutting board and under the presser foot next to the first fabric; a) operating the sewing machine to feed the first and second panels through a reciprocating needle to form a substantially straight stitch joining the first and second panels together; b) guiding the first and second fabrics during the following steps: i) advancing the pleating tab toward the presser foot, thereby engaging the second fabric with the pleating tab and forming pleats of programmable length in the second fabric over the first fabric; ii) operating the sewing machine to feed the pleats in the second fabric and the reciprocating needle of the first fabric, and sew a required number of sewing threads to the pleats in the second fabric and the first fabric; iii) retracting the pleating tab away from the presser foot to form a curved stitch connecting the pleats in the second fabric to the first fabric; and Repeat steps a) to b) above to create a succession of straight and curved stitches to form a closed loop. 5. The method of claim 4 wherein the first fabric is the top decking fabric of the mattress and the second fabric is the gusset fabric used to attach the pillow top to the mattress. 6. The method of claim 4, wherein the first fabric is the top fabric of the quilt frame, and the second fabric is the border fabric of the quilt frame. 7. The method of claim 4, wherein the first fabric is the top decking fabric of a quilt frame and the second fabric is a European style top border fabric. 8. A method of sewing a mattress body top cover fabric to a mattress top border fabric using a sewing machine having a base plate, a presser foot, and a reciprocating needle, the method comprising: (a) positioning the top cover fabric on the sewing machine base plate under the presser foot; (b) positioning the border material above the cutting block supported above the base plate and under the presser foot adjacent to the upper deck material such that the needles are the desired distance from the edge of the border material; (c) use a sewing machine to sew straight stitches on the border fabric and the top deck fabric, the stitches being parallel to each other with the edges of the border fabric at the desired distance therebetween; (d) determine where the stitch begins at the corner of the upper facing fabric; (e) using the pleating device to form pleats of programmable length in the boundary fabric above the top decking fabric; (f) use a sewing machine to sew the required number of sewing threads in the pleats on the border fabric and in the top facing fabric; (g) manually guiding the border and top facing fabrics around the corner portions during the above process of forming the pleats and sewing the required number of sewing threads; (h) Repeat steps (e) through (g) above to create the desired number of pleats in the border fabric and the desired number of pleats in the border fabric and Sew a curved stitch on the top facing fabric at the desired distance from the edge of the border fabric. 9. The method of claim 8, further comprising repeating steps (c) to (h) to sew a stitch around the top facing fabric at a desired distance from the edge of the border fabric .

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